Gap filler for reciprocating floor slat conveyor

ABSTRACT

For use in a reciprocating floor slat conveyor system having formed slats made of steel, a gap filler for sealing the gaps between side-by-side steel slats includes a portion that extends upwardly into the gap, and a lower portion that is connected to one of the side-by-side slats. The gap filler is installed by pushing down the gap filler into the gap between slats.

TECHNICAL FIELD

This design relates to reciprocating floor slat conveyors.

BACKGROUND

Reciprocating floor slat conveyors are well-known. They consist of aseries of side-by-side floor slats that are all moved in one directionat the same time. This moves or conveys a load that rests on the floorslats. Then, a lesser number of floor slats is moved in the oppositedirection, sliding underneath the load. This is commonly done in sets ofthree, or in other words, one third of the slats are moved in theopposite direction, in sequence, until all are returned to their initialposition. Moving a lesser number of slats during the return sufficientlyreduces friction between the slats and the load above, such that theload holds its position during the return. Then, the slats are movedagain, all at the same time, to further carry the load, and so forth,with the sequence just described being repeated until the load is movedoff the reciprocating floor slat conveyor. Systems of this kind areoften installed in trailers for hauling and unloading bulk materials,although there are also many other kinds of applications, includingstationary applications.

The reciprocating floor slats are commonly made from extruded aluminum.However, there is a need and market for steel floor slats. Steel is abetter material for floor slats compared to aluminum and would be betterfor use in the solid waste industry. Regardless of the material that isused to manufacture the slats (i.e., aluminum vs. steel), the spacebetween individual slats (that are side-by-side each other in theinstalled conveyor) needs to be sealed. In the solid waste industry, forexample, where aluminum slats have been used, the seals between slatscan be the first thing to fail. The type of seal used for an aluminumslat does not translate for use in a steel slat for reasons relating todifferences between aluminum and steel.

The design disclosed here was created to fill the elongated space or“gap” between steel floor slats. The design solves a problem in that itenables the sealing of the elongated gap that is created betweenindividual, roll-formed steel slats. Roll-forming is a different processrelative to making extrusions.

Floor slats that are extruded from aluminum can be made with nonuniformwall thicknesses that include elongated seal-holding grooves orrecesses. These grooves or recesses can hold a gap-filling seal in placebetween aluminum slats that are arranged side-by-side across the widthof the reciprocating floor conveyor.

Referring to FIG. 22, as an example, which is labeled and acknowledgedto be “prior art,” a conventional aluminum slat (shown incross-sectional profile) is indicated at 1. The slat 1 rests upon abearing member 2. The bearing member 2 is supported by a square subdeckmember 3. The gap-filling seal is indicated at 4. As can be seen in thisFigure, the seal 4 has an enlarged portion 5 that is captured by arecess 6 in the aluminum slat 1. A split portion 7 of the seal fills thegap (indicated generally by arrow 8), which prevents material fromworking through the gaps between individual slats as they moveback-and-forth during operation of the conveyor (bear in mind that allof these components are elongated and extend lengthwise into the page).

Aluminum can be extruded to the slat form illustrated in FIG. 22 withthe seal-capturing recess 6. This is not workable for steel floor statsthat are roll-formed from harder and thicker steel alloys, becauseroll-forming has practical limitations that make it difficult to mimicwhat can be done (in terms of cross-sectional profile) in comparison toextruding aluminum.

A steel floor slat (that is roll-formed) is therefore likely to have aless complicated cross-sectional profile, relative to an extrudedaluminum floor slat, with the steel slat's top and side surfaces havingthe same thickness throughout, resulting from a single steel strip beingput through a roll-forming process that bends the steel into top andside sections. This creates a design problem for sealing the gapsbetween steel slats because, as indicated above, unlike extrudedaluminum, it is not workable to roll-form steel with the kind ofseal-holding pockets or recesses (i.e., reference number 6 in FIG. 22)that have been used in the past to seal gaps between aluminum floorslats in reciprocating conveyors.

The design disclosed here makes roll-formed steel slats practical intypical markets where reciprocating floor slat conveyors are used andoffers the advantage of using more-durable steel instead of aluminum,particularly when reciprocating floor slat conveyors are built intotrailers (or the like) that are used to haul and unload abrasivematerials. The design enables a simple steel slat profile to work inreciprocating floor slat conveyors.

SUMMARY

For use with a reciprocating floor slat conveyor that has reciprocatingfloor slats that are formed from steel, a gap filler that fills thespace between side-by-side slats.

The slats in the conveyor will have a lengthwise gap between adjacentside-by-side steel slats that enables the slats to move together, or inreciprocating fashion, according to conventional operation of theconveyor. The gap filler includes an upper portion that extends upwardlyinto the lengthwise gap. A lower portion of the gap filler, connected tothe upper portion as a single integrated piece, is wrapped around alower side edge of one of the side-by-side steel slats.

The lower portion of the gap filler is made to pinch the lower side edgeor sidewall of the steel slat, in the manner described below. Thisenables the gap filler to be pre-installed on the roll-formed steelslat. During the assembly sequence that involves installing roll-formedsteel slats side-by-side across a conveyor, the gap-filler's upperportion is initially elevated vertically relative to its finalinstallation position, which enables the combination of steel slat andgap filler seal to be installed during the assembly of the reciprocatingfloor conveyor.

Final installation involves pushing down the gap-filler's upper portion(or, in other words, pushing the gap-filler further downward into thegap between side-by-side floor slats). When this happens, the upperportion of the gap filler (in the gap between slats) shifts to close andseal the gap. At the same time, the lower portion of the gap filler isshaped to shift into place around the lower side edge or sidewall of thesteel slat, thereby holding the gap filler in position between the floorslats as they subsequently move together, or move relative to eachother, according to the operation of the reciprocating floor conveyor.As is described further below, this shifting movement (caused by pushingthe gap filler downward) involves the lower portion of the gap fillerhaving an angled surface that rotates to match a surface on the insideof the sidewall of the slat when the gap filler is pushed down. Thisserves to hold the gap filler in position so that it seals the floorslats properly during conveyor operation.

Like the floor slats, the gap filler is likely to be elongated, althoughlength of the gap filler is a variable. Near the end of the floor slat,however, the lower portion of the gap filler will be independentlyfastened to the floor slat, where hauled material drops off the conveyorsystem during the unloading process.

The gap filler design disclosed here makes reciprocating steel floorslats viable for other hauling markets. For example, the combination ofsteel slat, gap filler, and steel subdeck may enable the hauling ofheavier, high-impact materials. Supporting bearings, i.e., thecomponents that rest on the subdeck and provide a sliding surface forthe steel slats above, can be extruded as single-piece bearings (in lieuof two separate bearings) that are possibly installed on the subdeck atthe same time as individual steel floor slats. This may provide certainadvantages for the installer.

The above summary will be better understood upon review of the followingdescription which is to be read in conjunction with the illustrateddetails of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are described as follows, wherein like partsindicate like parts throughout, except where the text indicatesotherwise:

FIG. 1 is a cross-sectional view of a series of side-by-sidereciprocating floor slats;

FIG. 2 is an enlarged view of one floor slat of the overall floor slatconfiguration shown in FIG. 1;

FIG. 3 is a cross-sectional view of a subdeck component of the floorslat configuration shown in FIG. 1;

FIG. 4 is a cross-sectional view of floor bearing components of thefloor slat configuration shown in FIG. 1;

FIG. 5 is a cross-sectional view of a “gap filler” component of thefloor slat configuration shown in FIG. 1;

FIG. 6 is a view like FIG. 5, but without dimensions;

FIG. 7 is a cross-section view of two side-by-side reciprocating floorslats made from roll-formed steel, but with a different embodiment offloor bearing;

FIG. 8 is similar to FIG. 7, but illustrates another floor bearingembodiment;

FIG. 9 is similar to FIG. 7 but shows a roll-formed steel subdeck;

FIG. 10 is similar to FIG. 8 but shows a roll-formed subdeck;

FIG. 11 is a cross-sectional view of a single, roll-formed steel slat,and illustrates how the gap filler is attached to the slat;

FIG. 12 is a cross-section view that shows the initial position of thegap filler during the floor slat installation process;

FIG. 13 is an enlarged cross-sectional view of FIG. 12 and shows thefinal position of the gap filler during the floor slat installationprocess;

FIG. 14 is a cross-sectional view that is similar to FIG. 12, but showsan aluminum subdeck for supporting all-steel floor slats;

FIG. 15 is the same view as FIG. 14, but shows the final position of thegap filler, similar to FIG. 13;

FIG. 16 is a cross-sectional view similar to FIG. 14, but illustrateshow the gap filler seals a moving floor slat to a fixed slat on the sideof the conveyor;

FIG. 17 is the same view as FIG. 16, but shows the gap filler in itsfinal position after installation;

FIG. 18 is an enlarged pictorial view of the end of a roll-formed steelslat, with gap filler and end cap components exploded from the steelslat;

FIG. 19 is a cross-sectional view showing the final installation of thecomponents illustrated in FIG. 18;

FIG. 20 is a cross-sectional view of a floor bearing resting on analuminum subdeck component;

FIG. 21 is similar to FIGS. 12 and 20 in that this Figure is across-sectional view showing a slat/gap filler combination being pusheddown onto an aluminum subdeck member during a floor slat installationsequence; and

FIG. 22 is labeled “prior art” and is a cross-sectional view that showshow the gaps between side-by-side slats made of extruded aluminum havebeen sealed in the past.

DETAILED DESCRIPTION

Referring first to FIG. 1, each floor slat is generally identified byreference numeral 10. It is envisioned that the floor slat 10 will bemade of formed steel having the shape illustrated in the drawings.

Referring now to FIG. 2, each floor slat rests upon a pair of bearings12, 14, which further rest upon a subdeck component, indicated generallyat 16. As can be seen in FIG. 1, the floor slats are installed so that asmall or narrow gap (at the position indicated by reference numeral 18)will exist lengthwise between the sides 20, 22 of the slats. This gap isfilled by the component (“the gap filler”) indicated generally at 24 inFIGS. 5 and 6.

The narrow gap 18 between the floor slats is filled by an upper portion26 of the gap filler 24. The lower portion of the gap filler 24,indicated generally by reference numeral 28 in FIGS. 5 and 6, is wrappedaround a lower side edge 30 of the steel floor slat (see, e.g., FIG. 2).

Exemplary dimensions of the gap filler 24 are provided in FIG. 5. Whilethese dimensions may vary, it is envisioned that they will be sized sothat the lower portion 28 of the gap filler can snap-fit onto the lowerside edge 30 of the steel floor slat. This would allow the gap filler tobe preinstalled at the place of floor slat manufacture and then shipped,installed, to the end user.

When the floor slats 10 are installed in the manner illustrated in FIG.1, the upper portion 26 of the gap filler 24 vertically fills gap 18 andis captured in place. It is envisioned that the gap filler 24 can bemade from different materials ranging from metal (aluminum, for example)or high-density plastic. This is an ongoing matter of development andtest. High temperature UHMW plastic may be used for some haulingapplications like asphalt, for example.

Referring now to FIGS. 7 and 8, the subdeck component 16 previouslydescribed is illustrated as an aluminum extrusion. As an alternative,the subdeck component 16 could be made from rolled steel, which isillustrated at 32 in FIGS. 9 and 10.

In all the embodiments shown in FIGS. 7-10, the pair of bearings 12, 14(previously illustrated in FIG. 2) is replaced by a single bearingillustrated at 34. The single bearing 34 is shown as having two versions34A, 34B. According to the embodiments illustrated here, one version(34A) is designed to have longitudinal grooves 36, while the other (34B)lacks these specific grooves. Both versions (34A, 34B) of the singlebearing 34 have a central channel 38. In the embodiment that illustratesthe roll formed steel subdeck 32, the central channel 38 of the bearing34 rests on top of an upwardly projecting portion 40 of the subdeck (seeFIGS. 9 and 10). The bearing 34 is made of high density plastic orsimilar materials already known to be used in connection with makingreciprocating floor conveyors.

The dimensions of the gap filler 24 provided in FIG. 5 are applicable tothe embodiments illustrated in FIGS. 7-19. Referring now to FIGS. 11-13,installation of the gap filler 24 will be described in greater detail.

Referring first to FIG. 11, the roll-formed steel floor slat 10 is shownaccording to the configuration it would take following the roll-formingprocess, which would be known in the art. While the steel thicknessmight vary, a steel thickness of 3 millimeters may be typical. The steelslat has a top portion 42, opposite downwardly depending, vertical sideportions 44, 46, and inwardly bending lower side portions 48, 50.

The inwardly bending lower side portions 48, 50 define slants toward thecenter line of the slat 10. The opposite edges 49, 51 of these sideportions are spaced a certain distance apart and create an open width onthe bottom of the slat 10. This width opens into the hollow spacecreated by the slat's various walls 42, 44, 46, 48, 50, just described.

The vertical side portions 44, 46 of the steel floor slat 10 define the“gap” between the various steel slats 10 when installed as part of thereciprocating floor conveyor system. As is further described below, theinwardly bending side portions 48, 50 provide surfaces for connectingthe lower portion 28 of the gap filler 24 to the steel slat 10.

The left-hand side of FIG. 11 shows the gap filler 24 about to beconnected to the slat 10. The right-hand side of FIG. 11 shows the gapfiller 24 attached to the slat 10. There, the lower portion 28 of thegap filler 24 is wrapped around the slat's inwardly bending portion 50,with the slat's vertical side portion 46 being captured by the flex inthe gap filler 24, which pinches slat side portion 46 generally at thepoints indicated by arrows 52, 54, respectively. The gap fillerdimensions illustrated in FIG. 5 are sized to pinch a 3 millimeter steelslat, although these dimensions could be changed for differentinstallation configurations.

Continuing with FIG. 11, the right-hand side of the Figure shows how theslat/gap filler combination might be provided to an installer prior toinstallation of the slat/gap filler in a reciprocating floor conveyorsystem. It should be noted from the Figure that the vertical elevationof the gap filler's upper portion 26 at the top point (see referencenumeral 56) is close to the plane of the slat's load-bearing surface(reference numeral 58). There is also a space, indicated generally byarrow 60 in FIGS. 11 and 12, that is present between steel slat edgesurface 62 and gap filler surface 64.

FIG. 12 illustrates the same gap filler configuration described above,but with the steel slat 10 resting on the bearing 34 and steel subdeck32, side-by-side with the same slat/bearing/subdeck combination to theimmediate right. This is illustrative of the position of the gap filler24 during floor slat installation. It should be noted that, at thispoint, a narrow gap (indicated by arrow 61) still exists between theoutside surface 63 of the gap filler 24 and the outside surface 65 ofthe slat's sidewall 44. Then, the installer pushes down (see arrow 66 inFIG. 12) on the top 56 of the gap filler 24 to shift (some could call ita type of snap fit) the gap filler to the position shown in FIG. 13.There, the vertical elevation of the gap filler's upper portion 26 atthe top point 56 is pushed down below the plane of the slat'sload-bearing surface 58 and shifts slightly laterally to contact theside of the adjacent slat (see reference numeral 67 in FIG. 13), therebyclosing the narrow gap 61 described above; the previously described“pinch” between points 52 and 54 on the slat's side 46 moves down to theapproximate location of the bend between the slat's side 46 and inwardlybending portion 50; and gap filler surface 64 rotates and shiftsslightly so that surface 64 rests directly against slat surface 62 inlieu of the previously described space 60. This also creates a new spaceat the location indicated by arrow 68.

The angle of gap filler surface 64 (which could be called a positioningangle) and other gap filler dimensions are selected so that surface 64matches the angle of slat edge surface 62 after the shift (caused by theinstaller pushing the gap filler's upper portion 26 downwardly).Matching the angles of these surfaces keeps the upper portion 26 of thegap filler sealing the gap properly (between adjacent slats). Asindicated above, gap filler specifications are described in detaildirectly on FIG. 5. As indicated in the Figure, the positioning angle onthe gap filler 24 illustrated there is 37 degrees on a non-attached gapfiller. These dimensions could vary if other variations are made toother components.

FIGS. 14 and 15 illustrate the above gap filler installation for thealuminum subdeck configuration (FIG. 14 is a counterpart of FIG. 12while FIG. 15 is a counterpart of FIG. 13), while FIGS. 16 and 17illustrate the same installation but with fixed side slats 70, 72 thatwould be (typically) next to the bottom wall of a trailer, one on eachside. The trailer is not illustrated, but a person skilled in the artwould recognize that these Figures are representative of a larger numberof slats that span the distance, from side-to-side, within the trailer'swalls, which is typical for reciprocating floor slat systems. The numberof slats is usually defined by installation application.

FIG. 18 illustrates an end cap installation for steel slat 10. It iswell understood how bulk materials exit a reciprocating floor slatconveyor. In the present configuration, an end cap 74 has a portion 76that is inserted into the end 78 of the slat 10 (there would be nobearing structure at that location). The end cap 74 is held in place byfasteners 80, 82. A series of over-sized openings (indicated generallyat 84) in the lower portion 28 of the gap filler 24 at this end locationenables rivet fasteners 86, 88 to secure the gap filler 24 to the slat10 at the end location only. FIG. 19 shows the final end capinstallation in cross-section.

Finally, referring to FIG. 20, the single-piece bearing 34 describedabove is made to snap fit around subdeck lateral edges 90, 92. Thebearing 34 can flex at locations 94, 96 so that bearing portions 98, 100are captured in place by subdeck lateral edges 90,92. This is the samefor the steel subdeck configuration 32 previously described (see FIGS. 9and 10). The single-piece bearing 34 is otherwise captured within theperimeter or envelope defined by the top and side walls 42, 44, 46, 48,50 of the steel slat 10.

The side-to-side width of the bearing 34 is less than the width betweenthe opposite edges 49, 51 of the slat lower side portions 48, 50 thatwere previously described above (see FIG. 11, for example). Generallyspeaking, the side-to-side width of the bearing 34 is the distancebetween arrows 102 and 104 in FIG. 20. The idea is to create a bearingwidth within the envelope of the hollow slat 10 that is too wide for thebearing to be easily removed through the lower side of the slat. Whatthis means is that the plurality of bearings 34 that will be used for atypical conveyor installation may be inserted end-wise into the hollowslat 10. In such case, and referring to FIG. 21, the combination of slat10 and bearing 34 may then be installed onto the underlying subdeckstructure (whether it be aluminum or steel) at the same time bysnap-fitting the bearing onto the subdeck (while it is inside the slat10) and then later securing individual slats 10 to conveyor drivestructure (not shown in the drawings). The conveyor drive structure forreciprocating floor slat conveyors is well known in the art.

It is to be understood that the design is under development and test andmay change as the design is further developed. As an example, while thegap filler seal described above is intended to make steel slats acommercially viable design in the marketplace, it may later prove towork for aluminum slat configurations. For this reason, the foregoing isnot intended to limit patent protection. To the extent patent protectionis limited, all limits on patent protection are defined by the patentclaim or claims that follow.

What is claimed is:
 1. A process for installing roll-formed steel slatsin a reciprocating floor slat conveyor, the process comprising:providing a plurality of reciprocating floor slats that are roll-formedfrom steel, wherein each one of said roll-formed steel slats has auniform wall thickness, said slat having a top portion, a pair ofsubstantially vertical sidewall portions that depend downwardly fromopposite sides of said top portion, and a pair of inwardly slantingportions that respectively depend downwardly and inwardly from saidvertical sidewall portions, and with said inwardly slanting portionshaving end edges that are spaced apart; installing said slats with alengthwise gap between adjacent side-by-side slats; using a gap fillermember to seal said lengthwise gap between side-by-side slats, said gapfiller member having an upper portion that extends generally verticallyupwardly into said lengthwise gap, and said gap filler member furtherhaving a lower portion that is wrapped around an inwardly slantingportion of said slat, with said wall thickness of said slat beingpinched between an end of the lower portion and the upper portion ofsaid gap filler member, and wherein said upper portion of said gapfiller member is pushed down in said gap between slats in a manner so asto cause said upper portion of said gap filler member to seal said gapand said lower portion of said gap filler member to hold said upperportion in place within said gap.
 2. For use with a reciprocating floorslat conveyor, a combination comprising: a plurality of reciprocatingfloor slats that are roll-formed from steel, wherein each one of saidroll-formed steel slats has a uniform wall thickness, said slat having atop portion, a pair of substantially vertical sidewall portions thatdepend downwardly from opposite sides of said top portion, and a pair ofinwardly slanting portions that respectively depend downwardly andinwardly from said vertical sidewall portions, and with said inwardlyslanting portions having end edges that are spaced apart, and further,said slats being installed with a lengthwise gap between adjacentside-by-side slats; a gap filler member for filling said lengthwise gapbetween side-by-side slats, said gap filler member having an upperportion that extends generally vertically upwardly into said lengthwisegap, and said gap filler member further having a lower portion that iswrapped around an inwardly slanting portion of said slat, with said wallthickness of said slat being pinched between an end of the lower portionand the upper portion of said gap filler member; a slat bearing receivedwithin a space defined by said top portion, said vertical side wallportions, and said inwardly slating portions of said steel slat, withsaid slat bearing having a flat top surface upon which the steel slatrides, and further, said slat bearing having a side-to-side width thatis less that the width of said spaced apart end edges of said inwardlyslanting portions of said slat; and a steel subdeck member that supportssaid slat bearing.